Assembly for improved insulation

ABSTRACT

An insulated panel assembly having improved insulative R-value. The insulated panel assembly comprises a cover panel, a first insulation layer, and at least one additional insulation layer, wherein the at least one additional insulation layer has a higher R-value than the first insulation layer. The first insulation layer is secured to the cover panel. The first insulation layer further forms at least one recessed portion. The at least one additional insulation layer is positioned in the at least one recessed portion of the first insulation layer. Examples of the at least one additional insulation layer may include vacuum insulated panels and modified atmosphere insulation panels.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.17/024,040, filed Sep. 17, 2020, which is a continuation of U.S.application Ser. No. 16/278,247, filed Feb. 18, 2019, now U.S. Pat. No.10,822,807, each of which is hereby incorporated by reference in itsentirety.

BACKGROUND AND SUMMARY OF THE INVENTION

Exemplary embodiments of the present invention include systems andmethods for insulating an outer member (e.g., a panel, door, garagedoor, wall, etc.). Exemplary embodiments are described herein withrespect to a siding panel. Similar principles may also be applied withrespect to other types of outer members to achieve improved insulation.Accordingly, unless expressly set forth otherwise, exemplary embodimentsof the present invention are not limited to use with any particulartype, configuration, shape, size, material construction, or purpose ofouter member. For instance, examples of a siding panel are available ina number of shapes, configurations, and material constructions, and maybe used for a variety of residential, commercial, or other purposes.

An uninsulated siding panel typically has poor insulatingcharacteristics. For example, uninsulated siding panels comprised ofplastic (e.g., vinyl) or metal (e.g., aluminum, steel, etc.) often havea very low R-value. As a result, it is known to provide a foam panel onthe back of a siding panel to increase the insulating characteristics ofthe siding panel. For instance, one example of a foam backer may becomprised of expanded polystyrene (i.e., EPS) foam. In one example, theuse of an EPS backer may result in a siding panel unit or assembly(hereinafter referred to as a siding panel assembly for ease ofreference) having an R-value less than 3. The R-value is limited by thephysical dimensions and material composition of the foam backer.

There is a need to be able to increase the insulating characteristics ofan assembly comprising an outer cover (e.g., a siding panel assembly orinsulated panel assembly). There is also a need to be able to be improvethe insulating characteristics of an assembly comprising an outer cover(e.g., a siding panel assembly or insulated panel assembly) by providinga backer that is similar or smaller in size as compared to a traditionalfoam backer for the assembly. A need also exists to provide anotherinsulating material in addition to a foam backer for an assembly. Afurther need exists to integrate another insulating material with a foambacker for an assembly. In addition, there is a need to be able toincorporate higher R-value materials in an assembly comprising an outercover (e.g., a siding panel assembly or insulated panel assembly).Finally, there is a need for improved insulation assemblies that mayserve a variety of purposes.

Vacuum insulated panels (VIPs) are an established technology forincreasing R-value, but theft use is limited. VIPs are much betterinsulators than conventional products, but they are expensive, cannot bemodified or are difficult to modify in the field, and may show a loss ofperformance over time as the vacuum seal gradually degrades. For thosereasons, VPs are often a specialty product useful in some situations butnot as a replacement for conventional types of building insulation.

Some walls of houses, building walls, garage doors, and rooftops ofbuildings are often crowded with mechanical equipment and accesshatches, or may have other space limitations, which may make itdifficult if not economically impossible to achieve a high insulativevalue. There is a need to be able to effectively utilize insulation thathas high R-value when space is a key issue. For example, a high R-valuepanel effectively applied to the outside of a house may be enough tomeet current energy codes in the continental U.S., even if the house hasno cavity insulation.

Despite the advantages of VIPs, one major problem of using them are wallareas where standard sized sheets or half sheets will not fit. Somepotential solutions are to use modified atmosphere insulation panels(MAIs). MAIs may be a good candidate for next-generation insulationmaterials and may do so at a lower cost alternative to current vacuuminsulation materials. However, like VIPs, MAI sheets cannot be cut inthe field without piercing the barrier and losing the vacuum, thussignificantly degrading the R-value of the MAIs. In addition, theR-value of MAIs may also degrade over time. In addition, MAIs often havea non-stick cover that makes it difficult to secure the panel to anothersurface. There is therefore a need to be able to effectively utilizeMAIs, as well as VIPs or other high R-value insulation.

Exemplary embodiments of the present invention may satisfy some or allof these needs. For instance, an exemplary embodiment of an assemblycomprising an outer cover (e.g., a siding panel assembly or insulatedpanel assembly) may incorporate and integrate a higher R-value materialwith a backer that is comprised of a relatively lower R-value material(e.g., a foam backer). As a result of the higher R-value material insome exemplary embodiments, a resulting assembly may have a higherR-value as compared to a similar assembly having only a traditional foambacker. In another exemplary embodiment, a higher R-value material maybe included with a relatively lower R-value material to form a backerassembly, wherein the resulting backer assembly may have similar orsmaller physical dimensions than a traditional foam backer for that typeof outer cover. In such exemplary embodiments, a resulting assembly maystill have an equivalent or preferably higher R-value as compared to asimilar assembly having only a traditional foam backer. In yet anotherembodiment, a higher R-value material may be incorporated and integratedwith a relatively lower R-value material to form an insulation assembly,which may be useful for a variety of different purposes not limited to asiding panel assembly (e.g., cavity insulation, basement wallinsulation, garage door insulation, residential door insulation, etc.).

In addition to the novel features and advantages mentioned above, otherbenefits will be readily apparent from the following descriptions of thedrawings and exemplary embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front plan view of an exemplary embodiment of a siding panelassembly, which indicates a cross-section line A-A.

FIG. 2 is a cross-sectional view of the siding panel assembly of FIG. 1along line A-A, which further indicates a Detail B.

FIG. 3 shows Detail B of FIG. 2 , wherein the exemplary embodiment ofthe siding panel assembly comprises a first cover layer, a firstinsulation layer, at least one additional insulating layer, and a backcover.

FIG. 4 is a rear elevation view of the siding panel assembly of FIG. 1 .

FIG. 5 is a cross-sectional view of an exemplary embodiment of a sidingpanel assembly, which indicates a Detail C.

FIG. 6 shows Detail C, wherein the exemplary embodiment is similar tothe exemplary embodiment of FIGS. 1-4 except for the absence of a backcover.

FIG. 7 is a rear elevation view of the siding panel assembly of FIG. 5 .

FIG. 8 is a front elevation view of an exemplary embodiment of a sidingpanel assembly, wherein rear and interior details are indicated withdashed lines.

FIG. 9 is an end elevation view of the siding panel assembly of FIG. 8 ,wherein high R-value insulation material (within a cavity or pocket of afoam backer) is indicated with dashed lines.

FIG. 10 is an exploded view of an exemplary embodiment of a siding panelassembly.

FIG. 11 is a front elevation view of an exemplary embodiment of a sidingpanel assembly, wherein rear details are indicated with dashed lines andin which a cross-section line D-D is indicated.

FIG. 12 is a cross-section view of the siding panel assembly of FIG. 11along line D-D, which shows an example of how a first insulation panelwith pockets (e.g., holes) or other recesses may hold additionalinsulated panels having high R-value in place with or without the helpof a retention panel.

FIG. 13 is an isolated view of the exemplary embodiment of the foambacker in FIG. 12 , which shows an example of how a first insulationpanel may be shaped (e.g., molded or cut) to fit one embodiment such asby forming a pocket (e.g., a hole) or other recess for the insertion ofan additional insulated panel having high R-value.

FIG. 14 is an exploded view of the siding panel assembly of FIG. 11 ,wherein end caps or a sealant may be used to enclose the ends of thesiding panel assembly.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)

Exemplary embodiments of the present invention are directed toward theuse of the device described herein such as for a siding panel assemblyfor a house or building. For instance, examples of a siding panel areavailable in a number of shapes, configurations, and materialconstructions, and may be used for a variety of residential, commercial,or other purposes. However, as aforementioned, the benefits of anexemplary embodiment may also be applicable to other types of outermembers and purposes.

Turning now to the figures, the various embodiments of the inventionwill be described in particular. FIGS. 1-4 show an exemplary embodimentof siding panel assembly 10. The siding panel assembly 10 is comprisedof a siding panel 20 (i.e., a first or exterior cover layer or outermember or cover) and an insulation assembly 30. A siding panel 20 may bemolded to any desired shape. Moreover, the siding panel 20 and theinsulation assembly 30 may be formed so that they may be joined (e.g.,with an adhesive), interlocked, or otherwise connected with each otherin any suitable manner. For example, such as in this embodiment, aninsulation assembly 30 may be formed to generally conform and be secured(e.g., with an adhesive) to the inside of siding panel 20. In otherembodiments, an insulation assembly may have another desired shape suchas for another purpose.

In this embodiment, the siding panel 20 may provide a desired aestheticappearance such as for use on a home or other building. For instance, inone exemplary embodiment, a siding panel 20 (and siding panel assembly10) may be interlocked, joined, or otherwise connected to other similarpanels to completely cover the side of a home or building. The sidingpanel 20 may also assist in protecting the insulation assembly 30 fromdamage from the environment. The siding panel 20 (or other outer member)may be made of any material that meets the design specifications of thedesired use. Examples of materials that may be used to create the sidingpanel 20 may include, but are not limited to, vinyl, polyvinyl chloride,high density polyethylene, low density polyethylene, polypropylene,polyvinyl acetate, polystyrene, cured epoxy resin, shape memorypolymers, polymer composites (e.g., cellulosic and/or inorganic-filledcomposites), metals (e.g., aluminum, steel, etc.), shape memory metals,alloys, or other similar or suitable materials.

Insulation assembly 30 may be comprised of a first insulation layer 40and at least one higher R-value material layer 50 (i.e., an additionalinsulation layer). The first insulation layer 40 may be made of anysuitable insulative material. In one embodiment, the first insulationlayer 40 may be comprised of expanded polystyrene (EPS) foam. In otherexemplary embodiments, other suitable insulative materials may include,but are not limited to, molded fibers, wood, formed metals or alloys,polylactide, organic fibers such as wool or felt, molded paper board,and plastics. Still other materials that may act as a thermal insulatormay be used to create the first insulation layer 40. The firstinsulation layer 40 may be shaped (e.g., molded, cut, configured, etc.)in whatever design is suited for the intended purpose and use with theat least one additional insulation layer 50, as set forth herein.

In an exemplary embodiment, the additional insulation layer 50 mayincrease the insulative R-value of the insulation assembly 30 as well asthe siding panel assembly 10. The additional insulation layer 50 may becomprised of any material that will increase the overall R-value of theinsulation assembly 30 (as compared to only the first insulation layer40). In one embodiment, the additional insulation layer 50 may be a typeof vacuum insulated panel. In one example, the additional insulationlayer 50 may be integrated or otherwise incorporated with currentlyavailable or future insulated siding materials in order to develop asiding panel assembly with an R-value of >10 as determined by testmethod ASTM C1363.

More particularly, in one embodiment, a vacuum insulated panel (VIP) maybe a modified atmosphere insulation panel (MAI). MAI technology is atype of vacuum insulated panel (VIP) as discussed previously. Where someexamples of VIPs may use metal and air, some examples of MAIs may use ametal or polymer-coated foam. An example of a VIP may be created byremoving some of the air out of the panel and sealing it tightly whilemaintaining a vacuum in the panel. As a result, a VIP may have asignificantly higher insulation R-value as compared to traditional EPSfoam insulation. An example of a MAI panel may be formed by condensationof steam that replaces air. In one exemplary manufacturing method, thecore may be evacuated to approximately 50 mbar, followed by replacementof the remaining air with steam. Condensation of the steam during theforming step may create a final vacuum of approximately 5 mbars in oneexemplary embodiment. Overall, an example of a MAI Panel may providesimilar performance as other types of vacuum insulation panels, at40-50% less cost. However, unless expressly set forth otherwise, it isnot intended to limit a VIP or MAI panel to any particular materials,construction, manufacturing method, or degree of performance.

In one example, a MAI panel from NanoPore, Inc., measuring 6 inches wideby 24 inches long, may be used. The size of panels produced by NanoPoreis limited by their current manufacturing technology. However, othercompanies, such as Dow Corning, Inc. may produce panels of varying sizesand R-values. Accordingly, one skilled in the art may now or in thefuture purchase and/or make VIPs or MAIs of the size and R-value neededfor each desired embodiment.

The at least one additional insulation layer 50 is integrated orotherwise incorporated with the first insulation layer 40. For example,the at least one additional insulation layer 50 may be positioned in arecessed portion or portions 42 of the first insulation layer 40.Examples of a recessed portion 42 may include, but are not limited to,pockets, holes, cavities, slots, tracks, channels, openings, etc. FIGS.2 and 3 show one example of a cavity 42 in a rear surface of firstinsulation layer 40. In other embodiments, a recessed portion orportions 42 may be located in another location on a first insulationlayer 40 (e.g., a front surface, edge, or end of a first insulationlayer 40). Also, a recessed portion 42 may be contained within the edgeand end boundaries of a first insulation layer 40, or a recessed portion42 may extend through at least one edge or end boundary of a firstinsulation layer 40.

Furthermore, in some preferred embodiments, an at least one additionalinsulation layer 50 may be insertable and removable with respect to afirst insulation layer 40 as needed, such as during the installation ofa siding panel assembly. For example, a temporary retention system(e.g., tape) may be used to secure an at least one additional insulationlayer 50 in order to allow for insertion and removal, as needed (e.g.,to avoid cutting). In some other exemplary embodiments, an at least oneadditional insulation layer 50 may not be adapted to be removed from afirst insulation layer 40 and/or outer cover 20. For instance, in someother exemplary embodiments, an at least one additional insulation layer50 may be permanently secured to a first insulation layer 40 and/or anouter cover 20.

In the embodiment shown in FIG. 1 , insulation assembly 30 may furthercomprise an additional back cover layer 60 that is designed and formedto attach to the first insulation layer 40 and/or siding panel 20 andprovide support to keep the at least one additional insulation panel 50in place. In particular, in this embodiment, the back cover layer 60 isattached to the first insulation layer 40. The back cover layer 60 mayassist in supporting or otherwise holding the at least one additionalinsulation panel 50 in place such as by a physical locking or otherconnection to the siding panel 20 and/or first insulation layer 40,wherein other means of connection may include, but are not limited to,tape, mechanical (e.g., nuts and bolts, screws, nails, staples, hook andloop fasteners, etc.), adhesive (e.g., glue, resins, etc.), friction,and/or other similar or suitable means. In one exemplary embodiment, asaforementioned, a temporary retention system (e.g., tape) may be used tosecure a back cover 60 in order to facilitate insertion and removal ofat least one additional insulation layer 50, as needed (e.g., to avoidcutting).

The back cover 60 may be made of any material so long as it may beconnected to the first cover layer 20 and/or the first insulation layer40. In one exemplary embodiment, back cover 60 is comprised of the sameor similar material as first insulation layer 40. For example, oneembodiment of a back cover 60 may be comprised of EPS foam. Otherembodiments may utilize other suitable materials for a back cover 60,which may or may not be the same material used for a first insulationlayer 40. In some embodiments, a back cover 60 may not be comprised ofan insulative material.

FIGS. 5-7 show an exemplary embodiment that may be similar to theembodiment of FIGS. 1-4 except for the absence of a back cover 60. Inthis exemplary embodiment, the at least one additional insulation layer50 may be secured to the siding panel 20 and/or first insulation layer40 such as by a physical locking or other connection, wherein othermeans of connection may include, but are not limited to, tape,mechanical (e.g., nuts and bolts, screws, nails, staples, hook and loopfasteners, etc., preferably without compromising any vacuum), adhesives(e.g., glue, resins, etc.), and/or other similar or suitable means. FIG.7 shows an example where tape 70 is used to secure additional insulationpanels 50 to first insulation panel 40 and/or siding panel 20. Again, inan exemplary embodiment, the use of a temporary retention systemincluding, but not limited to, tape, may allow for installation andremoval of at least one additional insulation layer 50, as needed (e.g.,such as to avoid cutting).

FIG. 7 further shows an example of the use of multiple additionalinsulation panels 50 that are connected together. In other embodiments,the additional insulation panels in each row and/or column may beseparated (e.g., either in the same recessed portion or in separaterecessed portions). The use of multiple additional insulation panels 50may, for example, be necessary when such panels are a set size. Asaforementioned, it may also be possible to manufacture or acquire anadditional insulation panel of a desired size for an intended purpose,which may eliminate the need to use multiple additional insulationpanels.

FIGS. 8 and 9 show another exemplary embodiment of a siding panelassembly 100 a comprising a siding panel 120 a and a first insulationlayer 140 a. In these views, the additional insulation panels 150 a andother rear details are shown in dashed lines to facilitate illustration.In this exemplary embodiment, an upper row and a lower row of additionalinsulation panels 150 a are situated in recessed portions 142 a, 142 bin a front surface (i.e., adjacent to a rear surface of siding panel 120a) of first insulation layer 140 a. In this embodiment, the additionalinsulation panels 150 a in each row are connected together. In otherembodiments, the additional insulation panels 150 a in each row may beseparated (e.g., either in the same recessed portion or in separaterecessed portions). In this exemplary embodiment, the position of theadditional insulation panels 150 a on the front surface of firstinsulation panel 140 a allows for siding panel 120 a to assist withsupporting or otherwise holding additional insulation panels 150 a inrecessed portions 142 a, 142 b, which may be particularly beneficial fora vertical installation of additional insulation panels 150 a. Such aposition may also facilitate assembly of siding panel assembly 100 a.

FIGS. 8 and 9 also provide an example of a situation where additionalinsulation panels 150 a are a set size and do not properly fit at oneend of siding panel assembly 100 a. In particular, ends portions 152 aextend beyond one end of first insulation layer 140 a. In such anembodiment, those additional insulation panels 150 a may be modified(e.g., cut, trimmed, etc.), if necessary, to achieve a desirable size.In the case of a VIP or MAI panel that is not a proper size, a modifiedend may be resealed (e.g., taped; capped; bonded with an adhesive,resin, or glue; etc.) to limit the loss of insulative properties.Alternatively, in some other exemplary embodiments, those additionalpanels 150 a may, respectively, be overlapped with adjacent panels 150 ato avoid the need to cut.

FIG. 10 shows another exemplary embodiment of a siding panel assembly100 b that may be similar to siding panel assembly 100 a. Thisembodiment of siding panel assembly 100 b comprises a different sidingpanel 120 b and first insulation layer 140 b. This embodiment of firstinsulation layer 140 b has an upper recessed portion 142 c and a lowerrecessed portion 142 d in a front face, which are each set at an angle(i.e., inclined). The inclined angle, along with siding panel 120 b,assists with retaining additional insulation panels 150 b in recessedportions 142 c, 142 d. As a result of such features, this embodiment mayalso facilitate an easier assembly.

FIGS. 11-14 show another exemplary embodiment a siding panel assembly200. In this exemplary embodiment, a first cover layer 220 has a frontface 222 and a back face 224. The front face 222 may, for example, faceaway from a structure to which the siding panel assembly 200 may beattached. The back face 224 of the first cover layer 220 is attached tothe front face 244 of the first insulation layer 240. The first coverlayer 220 is attached to the first insulation layer 240 by the meansalready described, which may include, but are not limited to, tape,mechanical, adhesive, structural, and other similar or suitable means.In this embodiment, a rear face 246 of first insulation layer 240 formsrecessed portions 242 a, 242 b that are adapted to receive additionalinsulation panels 250.

The recessed portions 242 a, 242 b may have any suitable size and shapeto receive additional insulation panels 250. For example, in someexemplary embodiments, the size and shape may be such that additionalinsulation panels 250 may have some freedom of movement within recessedportions 242 a, 242 b (e.g., to allow for differences in expansion andcontraction rates between the materials, to facilitate removal of anadditional insulation panel 250, etc.). However, in other exemplaryembodiments, the size and shape of recessed portions 242 a, 242 b may besuch that there is a tighter fit with additional insulation panels 250(e.g., to assist with retention of additional insulation layers 250).

The exemplary embodiment of FIGS. 11-14 may be manufactured by anysuitable processes. For example, recessed portions 242 a, 242 b may beformed by molding or a wirecut process. Regarding an example made by awirecut process, the recessed portions 242 a, 242 b may extend throughthe end boundaries of first insulation layer 240 as a result of theprocess. In that event, additional insulation layers 250 may be placedor slid into position in recessed portions 242 a, 242 b.

In addition, FIGS. 12 and 14 show that at least one optional rear backcover may be used to assist in securing the additional insulation panels250 to the first insulation panel 240. In this example, rear back covers260 a, 260 b are, respectively, adapted to support or otherwise holdadditional insulation panels 250 in recessed portions 242 a, 242 b. Inone example, each rear back cover 260 a, 260 b may have a front face 262a, 262 b that may be shaped to match or mate with the shape of the rearface 246 of the first insulation panel 240 when the first insulationpanel 240 has the additional insulation panels 250 inserted in it. Forinstance, in this exemplary embodiment, rear face 246 forms steps 248 a,248 b, 248 c, 248 d that are adapted to facilitate reception of rearback covers 260 a, 260 b. More particularly, in this exemplaryembodiment, recessed portion 242 a forms steps 248 a, 248 b that areadapted to receive front face 262 a of rear back cover 260 a, andrecessed portion 242 b forms steps 248 c, 248 d that are adapted toreceive front face 262 b of rear back cover 260 b. However, in otherembodiments, each recessed portion 242 a, 242 b may have any suitableshape that facilitates the reception of an additional insulation panel250 (with or without a rear back cover 260 a, 260 b), and each rear backcover 260 a, 260 b may have a front face of any suitable shape anddesign that allows for support of an additional insulation panel 250.For example, in some other embodiments, rear back covers 260 a, 260 bmay not be received in recessed portions 242 a, 242 b. Whether or notreceived in recessed portions 242 a, 242 b, the at least one rear backcover 260 a, 260 b may be attached to first cover layer 220 and/or firstinsulation panel 240 by any suitable means including, but not limitedto, a physical locking or other connection to the first cover layer 220and/or first insulation layer 240, wherein other means of connection mayinclude, but are not limited to, tape, mechanical (e.g., nuts and bolts,screws, nails, staples, hook and loop fasteners, etc.), adhesive (e.g.,glue, resins, etc.), friction, and/or other similar or suitable means.For example, in this embodiment, an adhesive (e.g., glue) or other meansof connection may be used on steps 248 a, 248 b, 248 c, 248 d to securerear back covers 260 a, 260 b. In another exemplary embodiment, asaforementioned, a temporary retention system (e.g., tape) may be used tosecure each back cover 260 a, 260 b in order to facilitate insertion andremoval of at least one additional insulation layer 250, as needed(e.g., to avoid cutting).

FIG. 14 further shows an example of end caps 270 a, 270 b, 270 c, 270 dthat may be used to seal the ends of the siding panel assembly 200(e.g., to minimize the effect the environment, to improve insulationproperties, and/or to assist in retaining additional insulation layers250). End caps 270 a, 270 b, 270 c, 270 d may be secured to first coverlayer 220 and/or first insulation layer 240 such as by a physicallocking or other connection, wherein other means of connection mayinclude, but are not limited to, tape, mechanical (e.g., nuts and bolts,screws, nails, staples, hook and loop fasteners, etc.), adhesive (e.g.,glue, resins, etc.), friction, and/or other similar or suitable means.In one exemplary embodiment, a temporary retention system (e.g., tape)may be used to secure each end cap 270 a, 270 b, 270 c, 270 d in orderto facilitate insertion and removal of at least one additionalinsulation layer 250, as needed (e.g., to avoid cutting).

End caps 270 a, 270 b, 270 c, 270 d may be manufactured from anysuitable material. In an exemplary embodiment, the material used may besubstantially the same or similar as the material used to make the firstinsulation layer 240. For one example, end caps 270 a, 270 b, 270 c, 270d may be comprised of EPS foam. However, in some other embodiments, thematerial used may be different than the material used for the firstinsulation layer 240.

Furthermore, either alternatively or additionally, the ends of thecompleted insulation panel may be sealed with any sealant that iscompatible with the materials used to make the first cover layer 220and/or first insulation layer 240. For example, the end caps 270 a, 270b, 270 c, 270 d may contain (e.g., a self-sealing cap) or be securedwith a sealant to ensure the end caps fit tightly to the siding panelassembly 200. However, other exemplary embodiments (i.e., that have atleast one recessed portion that extends through an end boundary of afirst insulation layer) may be sealed (e.g., with adhesives, resins,glues, tape, etc.) without the use of an end cap, or may not even besealed at the end of the first insulation layer. For example, in someembodiments, another accessory or panel may cover an end of the firstinsulation layer.

In one exemplary embodiment, it is particularly beneficial to form afirst insulation panel of an expanded polystyrene (EPS) foam tofacilitate reception and/or retainment of VIP or MAI panels. The EPSfoam panels may be readily manufactured with a recessed portion (e.g.,such as may be formed by molding or cutting) to receive a MAI or VIPpanel. In an exemplary process, these first insulation panels may thenbe easily introduced into an insulated siding assembly process. Forexample, by modifying various EPS foam board profiles, a system may bedesigned to mate or otherwise work with various siding products. As aresult, at least one recess in the EPS foam board may house the VIP orMAI panel(s), which may eliminate the need to try to glue VIP or MAIpanels to the backside of a vinyl panel.

In an exemplary process, the EPS foam cavity may easily be integratedinto a pre-assembly operation allowing someone to install the VIP or MAIpanels into the cavity of the EPS foam. This composite insulationassembly may then be subsequently run through the assembly line at theconstruction or installation site without making any changes to theprocess.

One weakness of a MAI panel is that it relies on vacuum as part of themechanism to develop high R-value ratings. Because siding panels mustsometimes be cut to suit the application, the VIP or MAI panels in someembodiments may be compromised. In that event, some of the insulatingproperties may be retained or recovered such by taping or otherwisesealing the sides which are cut. Alternatively, some embodiments mayallow for the VIP or MAI panels to be removed prior to cutting.

In another embodiment, an EPS insulation panel may be designed thatencapsulates the VIP or MAI panel, but also allows it to move within thebody of the foam. In such an embodiment, an installer may slide the cutVIP or MAI panels out of position to tape or otherwise seal them, thenslide the panels back into place and either cover the opening with acover and/or cap or leave it open. As another example, if there is room,an installer may instead slide or otherwise take an entire VIP or MAIpanel out of the assembly before making the end cuts, and then re-insertthe VIP or MAI panel into position (e.g., with some overlap with anadjacent VIP or MAI panel to account for the reduced length of the foamand siding panel).

In an exemplary embodiment, an EPS foam board may also facilitate theformation one large recess or at least one set of smaller recesses.Moreover, a recess may readily be formed in the back side, front side,end, or edge of a foam board. In the backside of the board of oneembodiment, a recess may not interfere with the assembly process interms of gluing the siding panel to the foam board. Such an embodimentmay also allow an installer an opportunity to possibly remove the VIP orMAI panels prior to cutting and/or to seal (e.g., tape) any cut ends ofthe VIP or MAI panels. On the other hand, a front side recess maypotentially facilitate easier assembly since the back side of an EPSboard is commonly flat and does not have the assistance of a sidingpanel to assist with retention of a VIP or MAI panel.

Many exemplary embodiments have been described with respect to sidingpanel assemblies. However, as aforementioned, other types of outercovers (e.g., other types of panels, doors, garage doors, walls, etc.)may also be used. For example, an insulation assembly may also be usedfor other purposes including, but not limited to, cavity insulation,basement wall insulation, garage door insulation, residential doorinsulation, etc.

Any embodiment of the present invention may include any of the optionalor preferred features of the other embodiments of the present invention.The exemplary embodiments herein disclosed are not intended to beexhaustive or to unnecessarily limit the scope of the invention. Theexemplary embodiments were chosen and described in order to explain someof the principles of the present invention so that others skilled in theart may practice the invention. Having shown and described exemplaryembodiments of the present invention, those skilled in the art willrealize that many variations and modifications may be made to thedescribed invention. Many of those variations and modifications willprovide the same result and fall within the spirit of the claimedinvention. It is the intention, therefore, to limit the invention onlyas indicated by the scope of the claims.

What is claimed is:
 1. An insulated panel assembly comprising: a firstcover layer; a first insulation layer secured to the first cover layer,the first insulation layer comprising a front face, a rear face, a firstend, a second end, and at least one recessed portion in the front face,the rear face, the first end, or the second end; and at least oneadditional insulation layer positioned in the at least one recessedportion of the first insulation layer and secured to the first coverlayer or the first insulation layer by a means of connection selectedfrom the group consisting of tape, mechanical fasteners, and adhesives,or by being interlocked with the first cover layer or the firstinsulation layer; wherein the at least one additional insulation layerhas freedom of movement within the at least one recessed portion toallow for differences in expansion and contraction rates between the atleast one additional insulation layer and the first insulation layer;and wherein the at least one additional insulation layer has a higherR-value than the first insulation layer.
 2. The insulated panel assemblyof claim 1 wherein the at least one additional insulation layer is avacuum insulated panel.
 3. The insulated panel assembly of claim 1wherein the at least one additional insulation layer is a MAI panel. 4.The insulated panel assembly of claim 1 wherein the first cover layer isa siding panel.
 5. The insulated panel assembly of claim 1 wherein thefirst insulation layer is comprised of expanded polystyrene foam.
 6. Theinsulated panel assembly of claim 1 or 5 further comprising: a backcover secured to the first cover layer or the first insulation layer toassist with retaining the at least one additional insulation layer inthe at least one recessed portion of the first insulation layer.
 7. Theinsulated panel assembly of claim 6 wherein the back cover is comprisedof a same material as the first insulation layer.
 8. The insulated panelassembly of claim 6 wherein the back cover is secured to the first coverlayer or the first insulation layer by tape such that the tape isadapted to be removed to facilitate removal of the back cover.
 9. Theinsulated panel assembly of claim 1 wherein the at least one recessedportion is in the front face of the first insulation layer.
 10. Theinsulated panel assembly of claim 9 wherein: the front face of the firstinsulation panel has a portion set at an inclined angle; and the atleast one recessed portion is positioned in the portion set at inclinedangle.
 11. The insulated panel assembly of claim 1 wherein the at leastone recessed portion is in the rear face of the first insulation layer.12. The insulated panel assembly of claim 1 wherein the at least onerecessed portion is in at least one of the first end and the second endof the first insulation layer.
 13. The insulated panel assembly of claim1 wherein the at least one additional insulation layer is removable fromthe at least one recessed portion of the first insulation layer.
 14. Theinsulated panel assembly of claim 13 wherein the at least one additionalinsulation layer is secured in the at least one recessed portion by tapesuch that the tape is adapted to be removed to facilitate removal of theat least one additional insulation layer from the at least one recessedportion of the first insulation layer.
 15. The insulated panel assemblyof claim 1 wherein the at least one additional insulation layer ispermanently secured in the at least one recessed portion of the firstinsulation layer.
 16. The insulated panel assembly of claim 1 whereinthe at least one additional insulation layer is secured to the firstcover layer or the first insulation layer by at least one mechanicalfastener selected from the group consisting of nuts and bolts, screws,nails, staples, and hook and loop fasteners.
 17. The insulated panelassembly of claim 1 wherein the at least one additional insulation layeris secured to the first cover layer or the first insulation layer by atleast one adhesive selected from the group consisting of glues andresins.
 18. The insulated panel assembly of claim 1 wherein: the firstcover layer is a vinyl siding panel; the first insulation layer iscomprised of expanded polystyrene foam; and the at least one additionalinsulation layer is selected from the group consisting of vacuuminsulated panels and MAI panels.
 19. A siding panel assembly comprising:a siding panel; an expanded polystyrene foam layer secured to the sidingpanel, the expanded polystyrene foam layer comprising a front face, arear face, a first end, a second end, and at least one recessed portionin the front face, the rear face, the first end, or the second end; andat least one additional insulation layer positioned in the at least onerecessed portion of the expanded polystyrene foam layer and secured tothe siding panel or the expanded polystyrene foam layer by a means ofconnection selected from the group consisting of tape, mechanicalfasteners, and adhesives, or by being interlocked with the siding panelor the expanded polystyrene foam layer; wherein the at least oneadditional insulation layer has freedom of movement within the at leastone recessed portion to allow for differences in expansion andcontraction rates between the at least one additional insulation layerand the expanded polystyrene foam layer; and wherein the at least oneadditional insulation layer has a higher R-value than the expandedpolystyrene foam layer.
 20. The siding panel assembly of claim 19wherein the at least one additional insulation layer is a vacuuminsulated panel.
 21. The siding panel assembly of claim 19 wherein theat least one additional insulation layer is a MAI panel.
 22. The sidingpanel assembly of claim 19 further comprising: a back cover secured tothe siding panel or the expanded polystyrene foam layer to assist withretaining the at least one additional insulation layer in the at leastone recessed portion of the expanded polystyrene foam layer.
 23. Thesiding panel assembly of claim 22 wherein the back cover is comprised ofexpanded polystyrene foam.
 24. The siding panel assembly of claim 22wherein the back cover is secured to the siding panel or the expandedpolystyrene foam layer by tape such that the tape is adapted to beremoved to facilitate removal of the back cover.
 25. The siding panelassembly of claim 19 wherein the at least one recessed portion is in thefront face of the expanded polystyrene foam layer.
 26. The siding panelassembly of claim 25 wherein: the front face of the expanded polystyrenefoam layer has a portion set at an inclined angle; and the at least onerecessed portion is positioned in the portion set at inclined angle. 27.The siding panel assembly of claim 19 wherein the at least one recessedportion is in the rear face of the expanded polystyrene foam layer. 28.The siding panel assembly of claim 19 wherein the at least one recessedportion is in at least one of the first end and the second end of theexpanded polystyrene foam layer.
 29. The siding panel assembly of claim19 wherein the at least one additional insulation layer is removablefrom the at least one recessed portion of the expanded polystyrene foamlayer.
 30. The siding panel assembly of claim 29 wherein the at leastone additional insulation layer is secured in the at least one recessedportion by tape such that the tape is adapted to be removed tofacilitate removal of the at least one additional insulation layer fromthe at least one recessed portion of the expanded polystyrene foamlayer.
 31. The siding panel assembly of claim 19 wherein the at leastone additional insulation layer is permanently secured in the at leastone recessed portion of the expanded polystyrene foam layer.
 32. Thesiding panel assembly of claim 19 wherein the at least one additionalinsulation layer is secured to the siding panel or the expandedpolystyrene foam layer by at least one mechanical fastener selected fromthe group consisting of nuts and bolts, screws, nails, staples, and hookand loop fasteners.
 33. The siding panel assembly of claim 19 whereinthe at least one additional insulation layer is secured to the sidingpanel or the expanded polystyrene foam layer by at least one adhesiveselected from the group consisting of glues and resins.
 34. The sidingpanel assembly of claim 19 wherein: the siding panel is a vinyl sidingpanel; and the at least one additional insulation layer is selected fromthe group consisting of vacuum insulated panels and MAI panels.